AWEA Pre Show, New Orleans, LA May 23, 2016

Wind Generation Best Practice Series

Technical Training

© ABB
24 May 2016 | Slide 1
Wind Generation Best Practices
Agenda and Speakers

1:00-2:20 - Electrical balance of plant panel discussion moderated by Benny Nyberg

Matthew Vaughn Khundmir Syed Pat Hayes

Business Technical Sales Business

Development, and Applications Development,
Substations Engineer, Power Energy Storage
Conversion
Systems

2:20 – 2:40 – Break

2:40-3:00 – Life cycle management

Jeff Peterson Marzio Zambetti
Global Product Global Renewable
Line Manager - Segment Manager,
Wind Service Electrification Products

© ABB
24 May 2016 | Slide 2
 Part 1: Power Grid Integration Raleigh, NC

Electrical balance of plant

Technologies and best practices

© ABB
24 May 2016 | Slide 3
Collector Substation Challenges and Pitfalls

 Overall substation construction lead-times.

 Developers often under estimate the time and logistics
required to execute the substation portion of the project.

 Time required to fully execute the substation can be

equal to or even longer than the time to complete that
actual renewable facility.

 This is very common in the solar industry due to highly

efficient methods of design and install in the solar
market.

© ABB
24 May 2016 | Slide 4
Interconnection / collector substation
Project execution pitfalls

Goal:
Highlight pitfalls of renewable projects that developers and EPC’s commonly stumble
into, which can be avoided with some up front awareness & planning, and avoid
catastrophic schedule issues that could potentially endanger your PPA back feed dates.

© ABB
24 May 2016 | Slide 5
Interconnection / collector substation
Project execution pitfalls

Overall substation construction lead-times

 Developers often under estimate the
time and logistics required to execute the
substation portion of the project.

 Time required to fully execute the

substation can be equal to or even longer
than the time to complete that actual
renewable facility.

 This is more common in the solar

industry due to highly efficient methods of
design and install

© ABB
24 May 2016 | Slide 6
Interconnection / collector substation
Project execution pitfalls

Substation site location

 Logistics - Consider access of large and
heavy equipment to be shipped to site..
 Site conditions - Some investigation and a
small shift in site location can save 100’s
of thousand in site preparation and shorten
overall lead-time.
 Note: If you see large visible rock
sticking out of the ground, please try
to relocate the substation site!
 Utilities – Remote Sites can require long
lead-times for utility access.

© ABB
24 May 2016 | Slide 7
Interconnection / collector substation
Project execution pitfalls

Engineering will take longer than you think!

 Required engineering studies require time and information from
the developer/ EPC and utility.
 The equipment used within the Wind/Solar system impacts
everything inside of the substation.
 Equipment selection early is crucial to maintaining the schedule.
 Changing equipment during the preconstruction stage could
trigger the requirement of a new system study and delay the
delivery of your substation as well as add significant cost.
 Example: Inverter selection affects power quality and will
likely change the capacitor bank sizing, reactor sizing and
controls
 Substation require a multi-layered engineering review cycle from
many parties.
 Examples: Developer / EPC / Serving Utility / Locality
issuing permits.
 Reviews and approvals require a minimum of 10 days to
approve PER LEVEL OF APPROVAL

© ABB
24 May 2016 | Slide 8
Interconnection / collector substation
Project execution pitfalls

Local permitting
 Depending on the locality and their relationship to the
project this can be an easy process or become bureaucratic
nightmare.
 Consider that the level of review and lead-time involved will
vary greatly from location to location and consider a
contingency for this potential delay.
 Substation engineering deliverables will be required to meet
the localities requirements.  We need the
diagram for the
flux capacitor –
Rev 56

© ABB
24 May 2016 | Slide 9
 Part 1: Power Grid Integration Raleigh, NC

Wind Grid Integration Technologies

Reactive power compensation at POI

© ABB
24 May 2016 | Slide 10
Challenges facing project developers

 Guidelines to connect wind farms or solar plants are

implemented throughout the world
 Level of complexity vary by country and/or by region
 In some cases, advanced wind turbine converters or solar
inverters can satisfy grid requirements
 In other regions, dynamic reactive power control is needed
 Typical requirements include:
 HVRT or LVRT
 Power Factor Control
 Need to complete a system impact study and understand
what requirements your wind farm must meet to safely
connect to the grid

© ABB Group
May 24, 2016 | Slide 11
Example Interconnection Requirements
HVRT & LVRT

Comparison of HVRT and LVRT Requirements PREPA’s Voltage Ride-Through Requirements

Courtesy: National Renewable Energy Laboratories (NREL) and Puerto Rico Electric Power Authority (PREPA)

© ABB Group
May 24, 2016 | Slide 12
Example Interconnection Requirements
Voltage Regulation System (VRS)

Voltage Regulation System (VRS):

 Wind Generation facilities must have a continuously
variable closed loop control VRS.
 VRS set-point shall be adjusted between 95%-105% of
rated voltage at POI. Set-point shall be controllable by
SCADA.
 Voltage droop shall be adjustable between 0 to 10%.
 The VRS dead band shall not exceed 0.1%.

© ABB Group
May 24, 2016 | Slide 13
Example Interconnection Requirements
Reactive Power Capability

 Wind Generation Facility shall be able to

smoothly ramp the reactive power from 0.85
lagging to 0.85 leading at the point of
interconnection (POI).
 A part of that power factor range is usually
expected to be dynamic. This dynamic range
is generally determined based on studies.
 The requirement of MVAR capability at
maximum output shall be sustained
throughout the complete range of the WGF as
shown in the adjacent figure.

© ABB Group
May 24, 2016 | Slide 14
Dynamic reactive power control
What is a STATCOM?

 A member of the Flexible Alternating Current

Transmission Systems (FACTS) family of
devices used on alternating current electricity
transmission networks

 Is a power electronic based device (also

referred to as a voltage-source converter)

 Acts as either a SOURCE or SINK of reactive

AC power to an electricity network for
purpose of controlling voltage or power factor

© ABB Group
May 24, 2016 | Slide 15
STATCOM – Major Components

IGrid
AC Step-Up Transformer
 From 480 V to MV XT

Power Converters ~
 IGBT power electronic ‘switches’
 Controls and Aux Power

=
DC Capacitor

© ABB Group
May 24, 2016 | Slide 16
Principle of Operation

V1/δ1 P V2 /δ2
Power flow

If Vconv > V2,Q Capacitive

Vconv < V2,Q Inductive

V21Vconv 2
2 V2
Q
P= cos
sin (δ 1 − δ 2 ) -
XX12 X Vconv
AC
DC

STATCOM
STATCOM SC
SVC TCSC

© ABB Group
May 24, 2016 | Slide 17
STATCOM V-I CHARACTERISTICS

V (PU)
1.4

1.2 Vref
System (Grid) Voltage

0.8
Slope
0.6

0.4

0.2

0
-1.5 -1 -0.5 0 0.5 1 1.5
Statcom Current (PU)

INDUCTIVE CAPACITIVE
© ABB Group
May 24, 2016 | Slide 18
STATCOM V-I CHARACTERISTICS

V (PU)
1.4

Weaker grid
1.2
Stronger grid
System (Grid) Voltage

0.8

0.6

0.4

0.2

0
-1.5 -1 -0.5 0 0.5 1 1.5
Statcom Current (PU)

INDUCTIVE CAPACITIVE

© ABB Group
May 24, 2016 | Slide 19
STATCOM V-I CHARACTERISTICS

V (PU)
1.4

V4
1.2
C A V3
System (Grid) Voltage

1 B
V1
0.8 V2

0.6

0.4

0.2

0
-1.5 -1 -0.5 0 0.5 1 1.5
Statcom Current (PU)

INDUCTIVE CAPACITIVE
© ABB Group
May 24, 2016 | Slide 20
STATCOM V-I CHARACTERISTICS

© ABB Group
May 24, 2016 | Slide 21
Applications of STATCOMs
Voltage control and reactive power management

Renewables Utilities Industrial

 Enables grid code  Utility grid compensation for  Industrial grid support and
compliance in wind and fluctuating loads, particularly power quality enhancement
solar plants in remote locations

© ABB Group
May 24, 2016 | Slide 22
ABB’s STATCOM Solution Applied
Naguabo, Puerto Rico

 A Puerto Rican wind farm required

dynamic reactive compensation
support for power factor and voltage
control

 System comprised of
13 x 1.8 MW wind turbines
connected to a 34.5 kV collector grid
for a total capacity of 23.4 MW

 Dynamic simulations showed the

ABB STATCOM voltage control
system was able to meet PREPA’s
Minimum Technical Requirements

© ABB Group
May 24, 2016 | Slide 23
ABB’s STATCOM Solution Applied
PREPA Performance Requirements

LVRT Reactive Power Controls

 All generation to remain  The total power factor  STATCOM system

online and be able to
ride-through faults down
to 0.0 per-unit
© ABB Group
May 24, 2016 | Slide 24
range shall be from 0.85 control is coordinated
lagging to 0.85 leading. with the wind park power
controller
ABB’s STATCOM Solution Applied
Naguabo, Puerto Rico

 ±12 MVAR ABB STATCOM

 1 x 5 MVAR Switched
Capacitor Bank

 1 x 4 MVAR Reactor

 STATCOM system provided

reactive power and voltage
control

 Automatically used its rapid

speed of response and
overload to assist in LVRT
and HVRT

© ABB Group
May 24, 2016 | Slide 25
ABB’s STATCOM Solution
Benefits both plant and network performance

Renewable Plant Grid

STATCOM

And solving problems on the grid . . .

Solving problems in the Wind Farm . . .
 Grid Interconnection Requirements
 Fault Ride Through (LVRT & HVRT)
 Power Factor (voltage regulations)
 Power Quality (harmonics)
 Prevent grid system instability & network
imbalances
 Provide frequency and voltage control
 Reactive power control
 Active power regulation

© ABB Group
May 24, 2016 | Slide 26
 Part 1: Power Grid Integration Raleigh, NC

Battery Energy Storage in Wind Farms

Applications and case studies

© ABB
24 May 2016 | Slide 27
EssPro™ Energy Storage Capabilities

Residential
loads

Solar power

Industrial Peak Shaving UPS

loads

Microgrids Load Levelling Capacity firming

Wind power

Power Station

Frequency Regulation Voltage Support

© ABB
24 May 2016 | Slide 28
ABB Energy Storage Experience
Saft / Cowessess Nation / SRC

 © ABB Group
 May 24, 2016 | Slide 29
Saft’s IM 20E Container
(1) X 200 kW / 372 kWHr
Customer needs
 400 kW / 744 kWh BESS
 Wind Integration.
 Customer wanted BESS to smooth out wind
turbine output.
 Demand Response
 Demonstrate Anti-Islanding functionality
Project Details
 Li-ion batteries

 Installed in 2012
(Inside)
ABB Scope
 400 kW PCS including (2) x 200 kW Indoor
units

 Includes inverters, dc contactors, ac circuit

breakers, control and external isolation/step-
up transformer to 23kV grid

© ABB
24 May 2016 | Slide 29
ABB Energy Storage Experience
Saft / Cowessess Nation / SRC BESS

GRID 25kV PCC LOAD

ABB Vantage
Controller

ABB ABB
EssPro PCS EssPro PCS

Customer Communication
& SCADA / PCC INFORMATION

© ABB
24 May 2016 | Slide 30
ABB Energy Storage Experience
Saft / Cowessess Nation / SRC

 © ABB Group
 May 24, 2016 | Slide 31

Courtesy of SRC

© ABB
24 May 2016 | Slide 31
Case study results: Canadian wind facility
Energy storage & power conversion system

Field Results - Smoothing

 Volatility was reduced by 64%
 Smoothing algorithm based on user
settable ramp rate limitations (i.e. 10%
over 1 minute)
 Ramp rates were shown to be limited by
a factor of 20
 Improved capacity factor and availability

© ABB
24 May 2016 | Slide 32
ABB Energy Storage Experience
SCE, LG Chem 8 MW / 9 MVA PCS

Customer needs
 DOE Smart Grid Program

ABB Scope
8 MW / 32 MWHr Tehachapi Storage Project
 ARRA funds
 (2) x 4 MW / 4.5 MVA PCS100 for BESS
 EssPro Vantage Controller
 DC Bus and Protection Circuit Breakers
 Mini-PCS System (100kW Indoor) w/ Site
Energy Control
 System Models, RTDS and Simulations
 Commissioning, Training and Installation
Supervision
 Li-Ion Batteries
 Installed in 2013

© ABB
24 May 2016 | Slide 33
ABB Energy Storage Experience
SCE, LG Chem 8 MW / 9 MVA PCS

 © ABB Group
 May 24, 2016 | Slide 34

© ABB
24 May 2016 | Slide 34
ABB Energy Storage Experience
SCE, LG Chem 8 MW / 9 MVA PCS

© ABB
24 May 2016 | Slide 35
ABB Energy Storage Experience
SCE, LG Chem 8 MW / 9 MVA PCS

 © ABB Group
 May 24, 2016 | Slide 36

8 MW / 32 MWHr Tehachapi Storage Project

© ABB
24 May 2016 | Slide 36
ABB Energy Storage Experience
SCE / LG Chem BESS
PCC 66kV
CT

Customer Communication
& SCADA / Data Historian
12 kV

ABB Vantage
Controller

ABB ABB ABB ABB

EssPro EssPro EssPro EssPro

© ABB
24 May 2016 | Slide 37
ABB Energy Storage Experience
SCE, LG Chem 8 MW / 9 MVA PCS

EssPro Vantage Controller

 Multiple Protocols

 Data Management

 Metering

Modes of Operation (8)

 Voltage Support / Grid Stabilization
 T-Line congestion mitigation
 Load Shifting
 RE Capacity Firming, Ramp Rates
 Frequency Regulation
Courtesy of SCE
 Spinning Reserve
 Energy Price Arbitrage

© ABB
24 May 2016 | Slide 38
ABB Energy Storage Experience
BESS Integrator / PJM (20 MW PCS)

Customer needs
 PJM Regulation Market
Project Details
 Li-ion batteries

 Installed in 2014

ABB Scope for Project Containing:

 (4) x 5000 kW Outdoor PCS / 35kV

 Includes inverters, dc circuit breakers, ac

circuit breakers, control, protection and
external isolation / step-up transformer to
(1) X 5000 kW PCS 35kV grid

 Metering / Data Management

 Noise suppression

© ABB
24 May 2016 | Slide 39
ABB Energy Storage Experience
BESS Integrator / PJM (20 MW PCS)

(4) X 5000 kW PCS

© ABB
24 May 2016 | Slide 40
 Questions?

© ABB
24 May 2016 | Slide 41
 Break

Jeff Peterson Marzio Zambetti

Global Product
Line Manager -
Wind Service

© ABB
24 May 2016 | Slide 42
 AWEA 2016
Turbine Retrofit/Upgrades

© ABB
24 May 2016 | Slide 43
AWEA 2016
Agenda – ABB Wind Turbine Retrofit/Upgrades

 ABB Company Overview

 Fixed Speed Turbine Retrofit
 Other Wind Services

© ABB
24 May 2016 | Slide 44
ABB in the Wind Power Industry
Full Electrical-only Supplier

Asset management
Substation automation
Collection grid and power quality
products HVAC* cables optimization solutions

Power systems
Offshore HVDC* consulting Offshore AC
converter station substation

Turbine control and HVDC* cables HVDC* Light,

PLC*
protection products HVDC* cables

Converters Communication Hybrid generation

Solutions, wind microgrid
power plant control
Motors
Control and network
Substation for management: SCADA*,
Generators onshore wind EMS*, GMS*
Transformers Generators Switchgears power plants

EMS: Energy Management System

GMS: Generation Mangement System
HVAC: High-voltage Alternating Current
HVDC: High-voltage Direct Current
PLC: Programmable Logic Controller
SCADA: Supervisory Control And Data Acquisition

© ABB
24 May 2016 | Slide 45
 ABB Wind Retrofit
Enable your fixed speed turbine to work at
variable speed, increasing efficiency and
lifetime
© ABB
24 May 2016 | Slide 46
ABB Wind Retrofit
Offering Description

 ABB can improve the wind performance and lifetime of an

old turbine by using new components and technologies
 Upgrade from stall/pitch controlled fixed speed to stall/pitch
controlled variable speed
 Wide power range : 200kW to 1300kW+
 Available for all turbine trademarks

© ABB
24 May 2016 | Slide 47
ABB Wind Retrofit
Constant vs Variable Speed

SOURCE: http://www.iqwind.com/index.php?categoryId=43263
© ABB
24 May 2016 | Slide 48
ABB Wind Retrofit
Increase efficiency and turbine lifetime

Scope Extend Life of Turbine Delivery

 Analysis  Refurbish and upgrade  Flexible packages for

 Consulting
 Engineering
 Design
 Project management
 Field commissioning
existing electrical and older generation turbines
mechanical components  Improve efficiency and
 Add full power converter reliability
that reduces mechanical  Meet grid code
stress on drivetrain compliance

© ABB
24 May 2016 | Slide 49
ABB Wind Retrofit
Full Power Converter System
Frequency Converter

medium voltage
switchgear

gearbox

line coupling
brake transformer

rotor bearing

© ABB
24 May 2016 | Slide 50
ABB Wind Retrofit
Full power converter concept (FPC) – Overview

Full power converter concept

 Decouples the generator from the grid
 All generated power flows through converter to the
grid
 Enables full reactive power production @ desired
PF
 Improved output power quality
 Converter provides generator’s torque and speed
control
 Noise reduction by avoiding harmful resonance
frequencies to the mechanical structure

Advantages compared to fixed speed turbines

 Satisfies grid code compliance
 Increased production (kWh) in terms of efficiency
by taking advantage of low and medium speed
winds
 Reduction in mechanical shocks and stresses on
turbine

© ABB
24 May 2016 | Slide 51
ABB Wind Retrofit
Reference – Before Retrofit

© ABB
24 May 2016 | Slide 52
ABB Wind Retrofit
Reference – After Retrofit

© ABB
24 May 2016 | Slide 53
Reference

NTR, Northern Ireland: 1 x V29 225 kW Retrofit

• Electrical Retrofit and Full power converter
installation
• Superior control system from DEIF
• Generator refurbishment

© ABB
24 May 2016 | Slide 54
Reference

Jofemar, Spain: 1 x V25

(150 kW) retrofit for micro
grid application
http://www.factorymicrogrid.
com/en/
 Electrical Retrofit and
Full power converter
installation
 Superior control system
from ABB
 Generator
refurbishment
 Integration in micro grid
(solar, EV charging,
etc.) done by others

© ABB
24 May 2016 | Slide 55
Reference

Chile Chico, Chile: 3 x V44 turbines (600 kW)

 Electrical Retrofit and Full power converter installation

 Mechanical Retrofit

 Superior control system from DEIF

 3x switch-rooms containing the MV switchgear and transformer (13.3

kV/690V) from ABB (pull-through)

© ABB
24 May 2016 | Slide 56
ABB Wind Retrofit
Conclusions

 Extend the life of your orphan turbines (NegMicon, Bonus, Vestas)

 Bring older turbines in to compliance with local grid codes
 Remove/minimize maintenance on ancillary grid support equipment
 Additional side benefit of potential power production by maximizing
power curve

© ABB
24 May 2016 | Slide 57
 ABB Wind Drive Upgrade
Optimize your ACS800-67
performance
© ABB
24 May 2016 | Slide 58
ABB Wind Drive Upgrade
Service offering

 Increase the availability of

your ACS800-67 by adding
new components reducing
its maintenance costs and
improving its efficiency

© ABB
24 May 2016 | Slide 59
ABB Wind Drive Upgrade
Service offering

 Brake Chopper upgrade

 Contactor upgrade
 NDCU Upgrade
 NETA-01 to -21
 Carbon Dust Exhaust
 Future Upgrades

© ABB
24 May 2016 | Slide 60
ABB Wind HW Upgrade
Contactor kit

Reduce maintenance costs and increase

reliability of the grid coupling
Benefits
Increased operational lifetime: With contactor kid
you increase the circuit breaker lifetime beyond the
turbine lifetime.
Optimized maintenance costs: Avoid extra costs
of the circuit breaker replacement.
Increased operational reliability: Contactor and
circuit breaker will perform for what they have been
designed.

© ABB
24 May 2016 | Slide 61
ABB Wind HW Upgrade
Brake chopper kit

Improve LVRT performance of your ACS800-67

Benefits
Improved performance: better
ride-through capabilities
Increased operational
reliability: Reduces the quantity
of overvoltage converter shut off

Optimized maintenance costs:

Avoid the component aging and
damaging caused by converter
trips.

© ABB
24 May 2016 | Slide 62
ABB Wind HW Upgrade
NDCU 33-CX

NDCU 33-CX replaces the NDCU 32/33

solution that was originally shipped with
converter.

Benefits
Increased operational reliability with the latest control board and
the new software.

Increased operational lifetime. The new control board increases

the NDCU lifetime beyond the operational lifetime of the wind
turbine.
Improved performance: The new processor, real time clock and
optimized software, allows the NDCU-33CX to perform better and
faster than its predecessor.
Better converter capabilities with lots of new parameters such us
AC & LVRT signals, system control inputs, crowbar stats…

© ABB
24 May 2016 | Slide 63
ABB Wind HW Upgrade
NETA 21

NETA 21 replaces the NETA 01 solution

and enables the real-rime Condition
Monitoring.

Benefits
Real-time Condition Monitoring:
Prevent failures and their
consequences.
Improved performance: Easier and
faster communication.
Increased customizing:
Create custom events and reports

© ABB
24 May 2016 | Slide 64
ABB Wind HW Upgrade
Carbon dust exhaust pipe

Keep your nacelle clean by installing the exhaust pipe

Benefits
Increased Reliability: Keeping the
nacelle clean means that there is no
dust that can damage the mechanical
or electrical components in the long
term.
Better safety and healthy
conditions

© ABB
24 May 2016 | Slide 65
 Generator Replace and recycle
ABB Wind Care – Generators :
Replace & Recycle Concept
© ABB
24 May 2016 | Slide 66
ABB Wind Care
Wind power generator: Replace and recycle concept

 When a wind power generator faces a damage, it causes

downtime up to 20 weeks and production losses
 To help our customers to overcome this problem, we have
created two storages for rapid replacement, one in Denmark
for 50 Hz, and one in USA for 60 Hz generators. We store few
different generator types of the largest fleets.
 The “recycle” means that we require the damaged ABB
generator for exchange, we repair and refurbish it, if possible
and feasible, and return it to the storage. If they are not
feasible to be repaired, we shall manufacture a new one for
the storage.
 If you want to guarantee the availability of the replacement
generator, you can buy them and make a hosting agreement
with ABB

© ABB
24 May 2016 | Slide 67
Marzio Zambetti - USA

Wind service
Electrification Products & Service
EP – Service
Main Pillar

Product Portfolio Documentation Go to Market

Replacement Value Proposition OEM

- ABB to ABB - Vestas
- ABB to Competitors - Gamesa
Spara parts - SWP
- Consumable System Integrator
- Components - DMDR
LCM - Ingeteam
- Retrofitting ISP
Utilities
Distributors

Connection among Distributors and Utilities

© ABB
May 24, 2016 Slide 69
Circuit Breakers & Switches - Service
Maintenance: Why Maintenance? Why Service?

Direct Cost

Maintenance: Personnel, Materials

• Health & Safety Risks

• Production Loss
• Reduced Life Time of Equipment

Indirect • Management of Urgency

costs • Energy Consumption

© ABB
May 24, 2016 Slide 70
Circuit Breakers & Switches – Service
Life Cycle Management

Normal production,
sales Active
and Classic Limited Obsolete
development phase
 Normal
 Product  Limited  Reduced
production,
maintenance production and availability of
 Sales and
phase guaranteed components and
 Development
availability of supports
phase
spares
 Standard Go to
MaRket

Product is Lifecycle Lifecycle Lifecycle

released for sale announcement announcement announcement

Granted Product Support Limited Product Support

© ABB
May 24, 2016 Slide 71
Circuit Breakers & Switches – Service
Life Cycle Management

Normal production,
sales Active
and Classic Limited Obsolete
development phase

New Emax
Emax

Emax 2
 EH 370 – EH 1200
 EHDB 520-960
 MEGAMAX
 ISOMAX up 800 A

PR122/P

AF Contactor  New Emax: Active until

end of June 2017
 Classic from 1st July
2017
 EK 370 -1000

Granted Product Support Limited Product Support

© ABB
May 24, 2016 Slide 72
Electrification Products – Service
Maintenance

 Component failure due to lack of maintenance

Corrective  Miss-used
Maintenance

Preventive Maintenence

© ABB
May 24, 2016 Slide 73
Eletrification Products– Service
Maintenance - Check List Emax / Contactor

Old Emax / New Emax Contactor AF range

 Ordinary Maintenance (cleaning & greasing) Ordinary Maintenance (cleaning & greasing)
 Visual Inspection
 Visual Inspection
 Trip Test
 Ekip T&P (new Emax)  Check the contact wear and arc chambers
 PR010/T (old Emax)
 Check the contact wear and arc chambers
 Electrical test of the accessories (YO, YU, AUX,
gear motor, etc..)
 Device locking, open-close the key locks
 Manual opening-closing of Emax (10 operations)

 Manual 1SDH000460R0002

© ABB
May 24, 2016 Slide 74
Eletrification Products– Service
Maintenance: Check List MCCBs < 630A- ISOMAX S7

TMAX < 630 A ISOMAX S7

 Visual Inspection  Ordinary maintenance (cleaning & greasing)

 Manual opening-closing operation (5 times)  Visual Inspection

 Trip Test:  Trip Test by PR010/T

 TMD: trip test by push button
 ELT: trip test by ekip T&P (or PR010/T for
Isomax)
 Electrical testing of accessories (YO, YU, AUX, Motor,
etc..)
 Electrical testing of accessories (YO, YU, AUX,
gear-motor, etc..)
 Device locking, open-close the key locks
 Opening-closing operation (10 times)

 Tightening of the screws and cables

 Manual

© ABB
May 24, 2016 Slide 75
Circuit Breakers & Switches – Service
Trainings

Online trainings
 Products and Features
 Where to find material/documents

Ordinary maintenance
 Getting into Service
 General Inspections
 Preventive Maintenance

Extraordinary maintenance
 Replacement of critical components (mechanism, poles,..)
 ABB Technicians Only

© ABB
May 24, 2016 Slide 76
Breakers and Contactors

Breakers Contactors

© ABB
May 24, 2016 Slide 77
Kits and testing equipment

Maintenance Kit & Greasing Kit Test Equipment

 Ekip T&P (New

Emax – Tmax)

 PR010T (Old Emax - Isomax)

© ABB
May 24, 2016 Slide 78
Circuit Breakers & Switches – Service
Retrofitting
Original Busbars

Existing Retrofill
Busbar Kit

LPBS GPG Service

May 24, 2016 | Slide 79
Circuit Breakers & Switches – Service
Available Documents

Wind Service Spare part

Service Manual Check List
Brochure Catalogue

WARNING! SAFETY DIRECTIVES

Before carrying out any maintenance work, it is necessary to complete the fol owing procedures:
– Ensure that incoming and out coming section are no longer energized
– Switch off the circuit breaker
– Rack the circuit breaker in "DISCONNECTED" position
– For extraordinary maintenance move the circuit breaker down of the nacelle to ensure safe and easy access to it
– Put into safety conditions in compliance with the standards and laws in force
ABB accepts no liability for damage to property or personal injury due to failure to comply with the instructions contained in this document.
These servicing procedures shall be handled only by qualified personnel with a thorough understanding of the equipment.
MOVING PART SERVICING PROCEDURES
General inspection and cleaning of the exterior
Check that there is not dust, dirt or carbon traces on the circuit-breaker. If present, remove dirt, oil traces or exceeding grease, with a clean dry cloth.
Remove grease or dust from plastic components with a clean dry cloth, alcohol and not aggressive products suitable for plastic components.
Check that the labels showing the technical characteristics of the circuit-breaker are present.
Clean circuit-breaker labels with a clean dry cloth.
Check that there are not overheating traces on the circuit-breaker isolation parts. These parts should be light grey in color.
Check that the circuit breaker contacts are intact. These contacts should be silver in color, with no traces of erosion or smoke.
Check the number of operations carried out
Operating Mechanism
Remove circuit breaker front cover
Remove coils holder
Discharge closing springs by closing and opening the circuit breaker
Dismantle Operating Mechanism and coupling pin
Remove grease or dust and, if present, oil traces or exceeding grease from internal components with clean dry cloth and laminated diluting
Clean and lubricate the opening and closing shafts, the hooks and other moving parts with grease type Exxon Mobil Mobilgrease 28
Check that all safety rings are in their place and that they are correctly installed
In case of excessive wear of any part replace the operating mechanism with a new one
Install operating mechanism lubricating coupling pin with grease type Exxon Mobil Mobilgrease 28
Check that screws of Operating Mechanism are tightened.
Check that the pin between operating mechanism and contacts rod is in place with its safety washer in place
Measure release close effort on closing button board
Measure release open effort on opening button board
Check that antipumping device works properly
Check the correct opening hook stroke
Check the correct charge springs pawl stroke
Check the correct knee-pad hook stroke
Check lubrication of the moving parts: Lubricate the bearings of the drive shaft with Exxon Mobil Mobilgrease 28 grease, including those on the circuit-
breaker sides

© ABB
May 24, 2016 Slide 80
EP Service
Extended Warranty

Products Whom Extend Warranty Condition

• Emax 2 Anyone can access to • +1 year free of The extended

the Extended charge if end user and warranty covers the
• New Emax
Warranty dedicated site details are circuit breaker and the
• Tmax (from T4 to tool : indicated in the WEB accessories ordered
T8) 1) ABB Local sales based tool à total already mounted on
Units number of warranty the circuit breaker
• Tmax XT
years = 2 years from ABB factory.
2) ABB Sales
Partners: Panel • +3 years with a To activate the
Builder, Original fee à total number of extension of warranty
Equipment warranty = 4 years is mandatory to
Manufacturer (OEM), • +4 years (at the register the product in
Wholesaler, Utility, same +3years) price if the WEB based
System Integrator, end user and site Extended warranty
EPC, Service details are indicated à tool .
Provides, etc… total number of
3) End users warranty years = 5
years

© ABB
May 24, 2016 Slide 81
Electrification Products– Service
US Service Team

Dean Sandefur
EPPC US Service
Manager
Mobile: 901-343-7674

Mark Gillim Kyle Streich

James Priest
Inside Sales/Service Service Center
BDM-North
Coordinator Coordinator
Mobile:517.270.3850
Office: 901.378.9193 Office: 662-548-2226

David Ray Eric Mills

BDM-South Service Center
Mobile:864.633.9666 Technician

Scott Fenley Gary Snyder

BDM-Central Service Center
Mobile:713.587.8349 Technician

Milenko Bistric Eddie Payton

BDM-West Mobile: Field Service
661.297.1288 Technician

Maurizio Signori
Field Service
Engineer
Electrification Products– Service
US Business Development Managers

Service Center

LPBS GPG Service South Haven, MS

May 24, 2016 | Slide 84
Electrification Products– Service
US Wind Installed Base

LPBS GPG Service

May 24, 2016 | Slide 85
Electrification Products– Service
US Distribution of ABB products

LPBS GPG Service

May 24, 2016 | Slide 86